Deformation Behavior of an Al-Ce-Fe-Ni-Zr Alloy Fabricated by L-PBF

Abstract The mechanical properties of a heat-resistant aluminum alloy Al-5.5%Ce-5.8%Fe-1.1%Ni-0.7%Zr fabricated by L-PBF were investigated under static and cyclic loading, considering the influence of build orientation and surface condition of the specimens. Moreover, deformation-induced microstructural changes in the alloy were analyzed. It was established that surface machining has little effect on the alloy’s strength but enhances its ductility, fatigue strength, and fatigue. The build orientation was found to affect ductility—samples fabricated in the horizontal direction exhibited approximately twice the plasticity compared to those built vertically, while strength characteristics and fatigue life remained nearly unchanged. During deformation, the following structural changes were observed: a pore-enriched zone formed near the fracture surface; the melt pools were elongated along the direction of the applied load; fine intermetallic inclusions of Al9FeNi, Al4Ce, and Al3Zr phases formed during L-PBF partially dissolved in the solid solution; the lattice parameter of the aluminum solid solution decreased, presumably due to the dissolution of Ni and Fe atoms; and the broadening of diffraction peaks of the aluminum solid solution increased.